Automobile wiring harness assembly is divided into two processes: subassembly and assembly

Subassembly process: mainly the assembly of electrical components.

1.Plug-in; 2. Install secondary locks/blind plugs/blind bolts.

Assembly process: mainly the assembly of coverings and fixings.

1.Assembly of coverings: winding of tape; installation of various pipes (corrugated pipes/PVC pipes/fiber pipes); installation of sheaths; 2. Installation of positioning parts/brackets.

Separate installation: plug-in

Matching of electrical components: to achieve circuit connection and smooth current flow.

Plug-in: insert the wire with terminals into the hole of the connector to achieve circuit connection and smooth current flow.

Plug-in method: three-step plug-in method

Correct plugging method:

1.Push; 2. Listen (when the terminal is plugged in, you will hear a “click” sound);

3. Pull back. * Note the finger-gripping technique and the vertical insertion angle in the picture.

Plug-in electrical test bench:

The electrical test bench must be released for quality before use, and there must be a quality release label on the electrical test bench.

The electrical test bench can detect whether the circuit is correct, but it cannot detect whether the terminal is plugged in properly.

How to complete the plug-in correctly:

1.Take the correct kanban line according to the process document.

2.Take the correct connector according to the process document.

3.Insert the kanban line into the correct hole according to the plug-in visual view and process document without missing any.

4.The three steps of plug-in must be performed to ensure that the plug-in is in place.

Sub-assembly process—-Installation of secondary lock/blind plug/blind bolt

Blind plug installation: Install to the correct hole position according to the process/visual view.

The blind plug should be lower than the end face of the connector and not damaged.

Blind bolt installation: Install to the correct hole position according to the process/visual view.

The blind bolt is plugged in place, in the correct direction, and not damaged.

Wrapping method: No reverse gluing is allowed when the tape is wrapped.

Bellows assembly:

When installing the bellows, you must use a tube installer. Do not scratch the wire when installing the bellows.

Fix the bellows at the branch node:

Sheath assembly:

Use the correct expansion tool according to the process requirements to avoid the wrong tool from damaging the terminal and rubber parts.

At the same time, be careful not to scratch the terminal when it passes through the via hole. At the same time, pay attention to the correct direction of the sheath.

The rubber parts should be wound to the root according to the process requirements, and the rubber parts should be

completely wrapped by the tape to avoid the rubber parts falling off due to incomplete winding.

Assembly of positioning parts:

Conclusion

The wiring harness industry is in a stage of rapid development. Trends such as intelligence, lightweight, high voltage, environmental protection and globalization will lead the future development direction of the industry. 

Hongchen Electronics has been continuously promoting technological innovation, improving product performance and reliability to meet market challenges and opportunities!

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